sirius fs 50-70 - potterton commercial

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Sirius FS 50-70Floor Standing Condensing Gas BoilersInstallation, Operation & Maintenance Manual

To be kept by the user October 2010

heating specialists

2912.822.1 - GBInstructIons pertaInInG to the user

Dear Customer,

We are sure your new boiler will comply with all your requirements.

Do not dispose of this booklet. This manual contains the information, which will help you to run your boiler correctly and efficiently.

potterton coMMercIaL boilers bear the CE mark in compliance with the basic requirements as laid down in the following Directives:- Gas Directive 90/396/EEC- Efficiency Directive 92/42/EEC- Electromagnetic Compatibility Directive 2004/108/EEC- Low Voltage Directive 2006/95/EC

Do not leave any parts of the packaging (plastic bags, polystyrene, etc.) within children’s reach as they are a potential source of danger.

ATTENTION

This boiler can only be installed and operatein permanently, ventilated rooms in accordance with

BS6644


1. Instructions prior to installation 42. Instructions prior to commissioning 43. Commissioning of the boiler 54. Filling the boiler 125. Switching the boiler off 126. Prolonged standstill of the system. Frost protection 127. Servicing instructions and gas change 12

8. General information 139. Instructions prior to installation 1310. Boiler installation and dimensions 1411. Chimney flue connection 2112. Connecting the mains supply 2313. Adjusting the gas valves and gas change 3014. Setting the boiler parameters 3215. Control and operation devices 3416. Positioning of the ignition and flame sensing electrode 3517. Check of combustion parameters 3518. Activating the chimney-sweep function 3619. Annual service 3620. Boiler schematic 3721. Illustrated wiring diagram 3822. Technical data 39

contents

instructions pertaining to the user

instructions pertaining to the installer


This boiler is designed to heat water at a lower than boiling temperature at atmospheric pressure. The boiler must be connected to a central heating system and/or to a domestic hot water supply system in compliance with its performances and output power.The boiler must be installed by a Qualified Service Engineer and ensure the following operations are carried out:

a) Check that the boiler is fit for operation with the type of gas available. For more details see the notice on the packaging and the label on the appliance itself.

b) Careful checking that the flue terminal draft is appropriate; that the terminal is not obstructed and that no other appliance exhaust gases are expelled through the same flue duct, unless the flue is especially desi-gned to collect the exhaust gas coming from more than one appliance, in conformity with the standards and regulations in force.

c) Careful checking that, in case the flue has been connected to pre-existing flue ducts, thorough cleaning has been carried out in that residual combustion products may come off during operation of the boiler and obstruct the flue duct.

d) To ensure correct operation of the appliance and avoid invalidating the warranty, observe the following precautions:

1. Heating circuit

1.1. New system Before proceeding with installation of the boiler, the system must be cleaned and flushed out thoroughly to

eliminate residual thread-cutting swarf, solder and solvents if any, using suitable proprietary products. To avoid damaging metal, plastic and rubber parts, use only neutral cleaners, i.e. non-acid and non

alkaline. The recommended products for cleaning are: SENTINEL X300 or X400 and FERNOX heating circuit restore. The use of this product must be strictly

in accordance with the maker’s directions. Finally the system must be dosed with a suitable inhibitor at 1% system volume.

1.2. Existing system Before proceeding with installation of the boiler, the system must be cleaned and flushed out to remove

sludge and contaminants, using suitable proprietary products as described in section 1.1. To avoid damaging metal, plastic and rubber parts, use only neutral cleaners, i.e. non-acid and non-

alkaline such us SENTINEL X100 and FERNOX heating circuit protective. To use this product proceed strictly in accordance with the maker’s directions. Dose with inhibitor.

Remember that the presence of foreign matter in the heating system can adversely affect the operation of the boiler (e.g. overheating and noisy operation of the heat exchanger).

Failure to observe the above will render the warranty null and void.

1. instructions prior to installation

Initial lighting of the boiler must be carried out by a qualified service engineer. Ensure the following operations are carried out:a) compliance of boiler parameters with (electricity, water, gas) supply systems settings.b) compliance of installation with the standards and regulations in force.c) appropriate connection to the power supply and earthing of the appliance.Failure to observe the above will render the warranty null and void.

2. instructions prior to coMMissioning


KEYS DISPLAY SYMBOLS

Central heating mode setting key

Data display reset key

Parameter setting key (increase value)

Parameter setting key (decrease value)

Program access and scroll key

Program access and scroll keys

Reset key

Domestic hot water temperature setting key

Central heating water temperature setting key

Domestic hot water on/off key

Resettable alarm warning

MAIN displaySECONDARY display

Flame present (on)

Outdoor temperature

Standby (off)

Operation in manual mode at minimum tem-perature

Operation in manual mode at the maximum temperature set

Operation in automatic mode

Operation in central heating mode

Operation in domestic hot water mode

0205

03_1

100

Figure 1

IMPORTANT: Domestic Hot Water (D.H.W.) instructions discribed here, are to be taken into account only if the boiler is connected to a D.H.W. production system.

To correctly light the burner proceed as follows:1) Provide power supply to the boiler;2) Open the gas cock;3) Follow the directions given below regarding the adjustments to be made at the boiler control panel.

3. coMMissioning oF the boiler


0205

03_0

800

Figure 2

• Automatic operation. Operation of the boiler is controlled by the timed program as described in point 3-5.1 “Daily timed program for operation of the central heating system”;

• Manual operation at the maximum temperature set. The boiler comes into operation regardless of the timed program set. The operating temperature is that set using the key (point 3-3: “Setting the maximum central heating temperature”);

• Manual operation at minimum temperature. The operating temperature is that set in point 3-6: “setting the minimum central heating temperature”.

• Standby. The boiler does not work in central heating mode, although the antifreeze function is still enabled.

(1) Domestic hot water on/off key: This key can be pressed to activate or deactivate this function, which is identified on the display by a black cursor line under the symbol .

(4) Reset key. In case of a fault, referred to in point 3-7 “Faults and resetting the boiler”, the boiler can be restarted by pressing this key for at least two seconds (see 3-8).

If this key is pressed with no fault present, the display will show the message “E153”, and the same key has to be pressed again (for at least two seconds) to restart the boiler.

(9) Data key. This key can be pressed repeatedly to display the following information: - Temperature (°C) of the domestic hot water ( ); - outdoor temperature (°C) ( ); only provided with the outdoor temperature sensor probe connected. Press either of the keys to return to the main menu.

Dash“Automatic mode”

active

(2) Central heating water temperature setting key. This key can be pressed to set the central heating water output temperature as described in point 3-3.

(3) Domestic hot water temperature setting key. This key can be pressed to set the domestic hot water temperature as described in point 3-4.

(10) Central heating mode operating key. The key can be pressed to activate four boiler central heating operating modes; these modes are

identified by a black cursor line underneath the relative symbol on the display, and are as follows:

3.1 description oF keys


• Press either of the keys to access the programming function; the display will show the letter P followed by a number (program line);

• Press the keys until the display shows P1, referring to the time to be set;

• Press the keys to set the time; on the display, the letter P will start to flash;

• Press the key to save and exit the programming function;

0205

03_0

700

Figure 3

3.2 setting the tiMe

- Press the key (2-figure 1) to set the central heating water temperature;

- Press the keys to set the temperature required;- Press either of the keys (1 or 10 - figure 1) to save and return to the main menu.

N.B – With the outdoor sensor connected, the key (2 - figure 1) can be used to shift the central heating curve. Press the keys to decrease or increase the room temperature in the premises to be heated.

3.3 setting the MaxiMuM central heating teMperature

- Press the key (3-figure 1) to set the maximum domestic hot water temperature;- Press the keys to set the temperature required;- Press either of the keys (1 or 10 - figure 1) to save and return to the main menu.

3.4 setting the MaxiMuM doMestic hot water teMperature


- Press either of the keys to access the programming function; a) press these keys until the display shows P11, referring to the program start time;

b) press the keys to set the time;- Press the key; the display will show P12, referring to the program end time;- Repeat the operations described in points a and b until the third and last cycle is reached (program line

P16);- Press the key to save and exit from the programming function.

3.5 setting the daily prograM For operation in central heating and doMestic hot water Modes

3.5.1 setting the daily times for central heating mode operation

3.5.2 setting the daily times for domestic hot water mode operation

- Factory setting of D.H.W. function is enable (ON) while is disabled D.H.W. daily times program. To enable D.H.W. daily times program see section 14 (parameter H91).

Setting the daily times for domestic hot water mode operation-Carry out the operations described in section 3.5.1 for program lines 31 to 36.

3.6 setting the MiniMuM central heating teMperature

- Press either of the keys to access the programming function;- Press these keys until the display shows P5, referring to the temperature to be set;- Press the keys to set the temperature required.This operating mode is enabled when minimum temperature central heating mode “ ” is activated or when the daily central heating program does not require heat.

N.B – With the outdoor sensor connected, parameter P5 can be used to set the minimum room tempe-rature in the premises to be heated (night set-back).


Range

0…23:59

25..80

00:00…24:00

00:00…24:00

00:00…24:00

00:00…24:00

00:00…24:00

00:00…24:00

00:00…24:00

00:00…24:00

00:00…24:00

00:00…24:00

00:00…24:00

00:00…24:00

0...1

Factorysetting

———-

25

6:00

22:00

0:00

0:00

0:00

0:00

0:00

24:00

0:00

0:00

0:00

0:00

0

Parameter description

Time of day setting

Minimum central heating temperature setting (°C)

Start of first daily period of automatic central heating

End of first daily period of automatic central heating

Start of second daily period of automatic central heating

End of second daily period of automatic central heating

Start of third daily period of automatic heating

End of third daily period of automatic central heating

Start of first daily period of domestic hot water production

End of first daily period of domestic hot water production

Start of second daily period of domestic hot water production

End of second daily period of domestic hot water production

Start of third daily period of domestic hot water production

Fine End of third daily period of domestic hot water production

Reset of daily central heating and domestic hot water production programs (factory settings). Press the - + keys together for about 3 seconds; the number 1 appears on the display. Confirm by pressing either of the keys

ParameterN.

P1

P5

P11

P12

P13

P14

P15

P16

* P31

* P32

* P33

* P34

* P35

* P36

P45

* Parameters for program lines P31 to P36 are displayed only if Domestic Hot Water (D.H.W.) program (pa-rameter H91 see section 14) is activated.

3.7 table For user-settable paraMeters


If a fault occurs, a flashing warning code appears on the display.The fault warnings appear on the main display (figure 1 a) together with the symbol (Figure 4).To reset, press the reset button for at least two seconds.

0205

03_0

500

Figure 4

0205

03_0

600

Figure 4.1

Fault warnings appear on the secondary display (figure 1 b) alternating with the time, both of them flashing (figure 4.1). It is not possible to reset malfunction warnings which appear on the secondary display as the cause of the alarm has first to be removed.

3.8 Fault warnings and resetting the boiler


(*) Auotoreset when fault disappears.

All the faults are displayed in order of importance; if several faults occur simultaneously, the first to be displayed is the one with highest priority. After the cause of the first fault has been removed, the second one will be displayed, and so on.If any given fault occurs frequently, contact the authorised Service Centre.

3.9 table oF Faults and error Messages

Corrective action

Call an authorised service centre (*).



Press the reset key (for about 2 seconds: if this device is triggered repeatedly, call the authorised service centre)

Call an authorised service centre.


Call an authorised service centre to check the gas pressure.

Press the reset key (for about 2 seconds); if the fault persists, call the authorised service centre to check polarity of ignition electrodes, ionisation current.

If symbol is displayed, press the reset button otherwise switch off the electricity supply to the boiler for at least 10 seconds; if the fault persists, call the authorised service centre.Check the positioning of the ignition and flame sensing electrode (see section 16).

Press the key again (about 2 seconds)

Press and hold reset button (2 seconds approx.) then press again when warning E153 appears


Check that the system is at the rated pressure. (Refer to the section on filling the system). If the fault persists, call the authorised service centre.

Description of fault

Outdoor temperature sensor fault

NTC output sensor failure

Hot water NTC sensor failure

Safety or flue gas thermostat tripped

Loss of flame during operation (the ionization current has fallen below the limit)

Minimum fan speed limit not reached

Gas pressure switch tripped / external thermostat tripped

No flame detected

Boiler circuit board error

The reset key has been pressed inappropriately

Internal error on boiler circuit module

Fan speed threshold not reached

Low water pressure

Errorcode

E10

E20

E50

E110

E128

E129

E132

E133

E151

E153

E154

E160

E164


To shut down the boiler switch off the electrical supply to the appliance.

IMPORTANT: Regularly check that the pressure displayed by the pressure gauge is 1 ÷ 4 bar when the central heating system is cold. Open the boiler drain cock to reduce pressure if it is too high. Open the filling cock to increase pressure if it is too low.Always open the filling cock very slowly to allow any air to bleed off.If the pressure in the system drops frequently, contact an authorised service centre to have the system chec-ked.

We recommend you avoid draining the whole system as raw water makeup will lead to harmful limestone de-posits inside the boiler and on the heating elements.In case the boiler is not operated during wintertime and is therefore exposed to danger of frost we suggest you add some specific-purpose anti-freeze to the water contained in the system (e.g.: propylene glycole coupled with corrosion and scaling inhibitors).The electronic management of the boilers includes a “frost protection” function in the central heating system which operates the burner to reach a heating flow temperature of 30° C when the system heating flow tempe-rature drops below 5°C.

The frost protection function is enabled if:* electrical supply to the boiler is on;* the gas service cock is open;* the system pressure is as required;* the boiler is not isolated.

To maintain efficient and safe operation of your boiler have it checked by a Qualified Service Engineer at the end of every heating season.Careful servicing will ensure economical operation of the system.Do not clean the outer casing of the appliance with abrasive, aggressive and/or easily flammable cleaners (i.e.: gasoline, alcohol, and so on). Always isolate the electrical supply to the appliance before cleaning it (see section 5 Turning off the boiler).

These boilers are produced for natural gas and can be converted to work with LPG (G 31).Any gas change must be effected by a Qualified Service Engineer.

4. Filling the systeM

5. switching the boiler oFF

6. prolonged standstill oF the systeM. Frost protection

7. servicing instructions and gas change

13912.822.1 - GBInstructIons pertaInInG to the InstaLLer

This boiler is designed to heat water at a lower than boiling temperature at atmospheric pressure. The boiler must be connected to a central heating system and/or to a domestic hot water supply system in compliance with its performances and output power.

IMPORTANT! The following components are not installed in the boiler as supplied. It is the installer’s responsibility to provide them:

• Expansion vessel;• Pressure safety valve;• Circulation pump;• Filling system cock.

Before connecting the boiler ensure the following operations have been completed:

a) Check that the boiler is fit for operation with the type of gas available. For more details see the notice on the packaging and the label on the appliance itself.

b) Check that the flue terminal draft is appropriate; that the terminal is not obstructed and that no other applian-ce exhaust gases are expelled through the same flue duct, unless the flue is especially designed to collect the exhaust gas coming from more than one appliance, in conformity with the standards and regulations in force.

c) Check that, in case the flue has been connected to pre-existing flue ducts, thorough cleaning has been carried out in that residual combustion products may come off during operation of the boiler and obstruct the flue duct.

The following remarks and instructions are addressed to Service Engineers to help them carry out a faultless installation. Instructions regarding lighting and operation of the boiler are contained in the ‘Instructions pertai-ning to the user’ section.Note that installation, maintenance and operation of the gas appliances must be performed exclusively by qualified personnel in compliance with current standards.Please note the following:• Install the boiler in a permanent ventilated central heating boiler room.• This boiler can be connected to any type of convector plates, radiators, thermoconvectors. Design the system

sections as usual though taking into account the available output / pump head performances, as shown in chapter 10.4.

• Do not leave any packaging components (plastic bags, polystyrene, etc.) within children’s reach as they are a potential source of danger.

• Initial lighting of the boiler must be effected by a Qualified Service Engineer.• Make sure that the room where the boiler is installed has a sufficient supply of air to ensure complete combu-

stion of the gas consumed by the appliance. Install unblockable ventilation grilles as necessary in accordance with the Rules in force.

• Connect the boiler directly to an efficient flue to vent all fumes and combustion gases outdoors. Make sure that the pipe connecting the boiler to the flue is not smaller in diameter than the boiler’s flue outlet. Make sure that the flue is in good condition and free from holes or cracks that could reduce draw.


8. general inForMation

9. instructions prior to installation


10. boiler installation and diMensions

Install the boiler in a position that ensures easy maintenance. You must be able to fully open the front access door and have adequate access to the rear of the boiler.If possible, install the boiler on a raised base of 200 mm in height to facilitate drainage of flue condensate.When calculating the weight of the boiler on the floor, bear in mind the weight of the water in the heat exchanger (see table 1).Adjust the levelling feet to compensate for any unevenness in the floor.

Install the necessary utility connections starting from the water and gas connections on the rear of the boiler (see table 1 for fitting type and size).

These appliances do not have any circulation pump, expansion tank or safety valve. These devices must therefore be provided elsewhere in the system, and must be sized to suit the system’s thermal capacity.

Connect the flue condensate drain pipe to a suitable water drain, ensuring an adequate slope.

To drain the boiler, use the drain tap at the rear.

To ensure correct operation of the appliance and avoid invalidating the warranty, observe the following precautions:

1. Heating circuit

1.1. New system Before proceeding with installation of the boiler, the system must be cleaned and flushed out thoroughly to

eliminate residual thread-cutting swarf, solder and solvents if any, using suitable proprietary products. To avoid damaging metal, plastic and rubber parts, use only neutral cleaners, i.e. non-acid and non

alkaline. The recommended products for cleaning are: SENTINEL X300 or X400 and FERNOX heating circuit restore. The use of this product must be strictly

in accordance with the maker’s directions. Finally the system must be dosed with a suitable inhibitor at 1% system volume.

1.2. Existing system Before proceeding with installation of the boiler, the system must be cleaned and flushed out to remove

sludge and contaminants, using suitable proprietary products as described in section 1.1. To avoid damaging metal, plastic and rubber parts, use only neutral cleaners, i.e. non-acid and non-

alkaline such us SENTINEL X100 and FERNOX heating circuit protective. To use this product proceeding strictly in accordance with the maker’s directions.

Remember that the presence of foreign matter in the heating system can adversely affect the operation of the boiler (e.g. overheating and noisy operation of the heat exchanger). Dose with inhibitor.



Figure 5

Table 1

Model Depth Height Widht Gas Fitting Fitting Water contents (mm) (mm) (mm) fitting F R ( l )

A (CH) (CH)

FS 50 621 850 450 G 3/4” G 1’’ G 1’’ 5,1

FS 70 693 850 450 G 3/4” G 1’’ G 1’’ 6,5

MR: heating flowRR: heating returnGAS: gas inlet to the boilerSC: condensate drain

Insert the flue-gas union and fasten the connector to the flue-gas thermo-stat

CT_

0804

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06_3

005


Figure 6

CT_

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202

10.1 hydraulic systeM 1

(Pumped heating circuits with remote control QAA73 or Room Thermostat, including hot-water tank, with primary loop)

Applications and Installation Details

- TS: Tank Sensor (QAZ36)*- B3: Room Control Module (QAA73)*- B1: Room Thermostat*- B9: Outdoor Temperature Sensor (QAC34) supplied with the boiler- P1: Heating Pump- PDHW: Hot Water Pump- PLP: Primary Pump

(*) Available Optional Extra

- Pumps, Hot Water Cylinder, Low Loss Header , Non return valve (Not supplied)- Installer Wiring ---------------

Applications (pumps, sensor, remote control ...) have to be connected to terminal as follows (see also section 12):

WITH QAA73 WITH REMOTE CONTROL ROOM THERMOSTAT APPLICATION TERMINAL BOARD TERMINAL BOARD PRIMARY PUMP PLP M1: A – B M1: A – B DHW PUMP PDHW M3: 13 – 14 M3: 13 – 14 HEATING PUMP P1 M3: 11 – 12 M3: 11 – 12 DHW SENSOR TS M2: 7 – 8 M2: 7 – 8 REMOTE CONTROL QAA73 M2: 1 – 2 NO ROOM THERMOSTAT M2: 3 – 4 OPEN M2: 3 – 4


Parameter changes requires (see also section 14):

PCB Description Setting Parameter PARAMETER

H552 Hydraulic system H552 = 2 (*) H553 KonfigHKS H553 = 21 (*) H615 KonfigAusgang H615 = 9 (*) H632 WANFO Q8 H632 = 00001100 (*)

(*) factory set


(Pumped heating circuits with Room Thermostats and compensated circuit with remote control QAA73, including hot-water tank, with primary loop)


- TS:Tank Sensor (QAZ36)*- B3: Room Control Module (QAA73)*- B1: Room Thermostat*- B9: Outdoor Temp Sensor (QAC34) supplied with the boiler- AGU2.500: Zone controller (Clip-in AGU2.500)*- FS: Flow Sensor (QAD36: supplied with the AGU2.500)*- P1: CTC Heating Pump- P DHW: Hot Water pump- PLP: Primary Pump- 3WV: 3-Way Valve (power open / power close) - P2: VTC Pump


- Pumps , Hot Water Cylinder, Low Loss Header, Non return valve (Not supplied)- Installer Wiring --------------

Figure 7

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203



APPLICATION TERMINAL BOARD PRIMARY PUMP PLP M1: A – B DHW PUMP PDHW M3: 13 – 14 HEATING PUMP P1 M3: 11 – 12 DHW SENSOR SB M2: 7 – 8 REMOTE CONTROL QAA73 (LOW TEMPERATURE) M2: 1 – 2 ROOM THERMOSTAT M2: 3 – 4 HEATING PUMP P2 CLIP IN AGU 2.500 3 WAY VALVE 3WV CLIP IN AGU 2.500 FLOW SENSOR FS CLIP IN AGU 2.500


PCB PARAMETER Description Setting Parameter H552 Hydraulic system H552 = 50 H553 KonfigHKS H553 = 12 H615 KonfigAusgang H615 = 9 H632 WANFO Q8 00001111


(Cascade with pumped heating circuits, Room Thermostats, primary loop)


- RT: Room Thermostat*- B9: Outdoor Temperature Sensor (QAC34) supplied with the boiler- OCI 420: Cascade interface controller (Clip-in OCI 420)*- RVA 47: Cascade controller (RVA 47)*- FS: Flow/return Sensor (QAD21)*- P1: Heating Pump- PLP: Primary Pump


- Pumps , Hot Water Cylinder, Low Loss Header, Non return valve (Not supplied)- Installer Wiring --------------


Figure 8

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204


APPLICATION TERMINAL BOARD PRIMARY PUMP PLP M1: A – B HEATING PUMP P1 RVA 47 ROOM THERMOSTAT RVA 47 FLOW/ RETURN SENSOR QAD 21 RVA 47


PCB PARAMETER Description Setting Parameter H552 Hydraulic system H552 = 80 H553 KonfigHKS H553 = 21 H615 KonfigAusgang H615 = 9 H632 WANFO Q8 00001111

If DHW circuit is required then DHW pump and DHW sensor have to be connected to terminal of RVA 47 Cascade Controller.

For more details refer to the instruction provided with the accessories RVA 47 and RVA 46 (compensated circuit).


10.4 exchangers pressure drop

FS 50 - 70 EXCHANGER PRESSURE DROP.

kpa Lit/sec kpa Lit/sec kpa Lit/sec kpa Lit/sec

Fs 50 50 0,97 32 0,71 25 0,53 10 0,35

Fs 70 60 1,41 35 1,03 20 0,77 11 0,51

Boiler hydraulic resistance and Water Flow rates 11°K ∆t 15°K ∆t 20°K ∆t 30°K ∆t

Fs 50 0,27

Fs 70 0,33

Boiler Minimum Water Flow rates Lit/sec

Exch

ange

rs p

ress

ure

drop

(mH

2O)

WATER FLOW RATE (l/h)

Graph 1

0712

_090

3


Connect the boiler to the flue using a pipe made of stainless steel or plastic material with an internal diameter of 80 mm, capable of resisting normal mechanical stresses over time, as well as high temperatures (<120°C) and the chemical effects of fuel gases and their condensates.Insert the flue-gas union and fasten the connector to the flue-gas thermostat before hooking up to the flue.Whenever possible use a flue connection that can be disconnected for maintenance.

Important! horizontal flue sections must have a minimum slope of 3° towards the boiler.

Flue accessories made of plastic material for cascade or single installations are available.

11. chiMney Flue connectionC

T_08

10 /

0902

_270

3

Figure 7a

0712

_090

5 / C

T_07

52

Max. length of flue duct (model HTE 45) : 30 m (L)Max. length of flue duct (model HTE 65) : 20 m (L)Each 90° bend reduces the duct max. length by : 1 mEach 45° bend reduces the duct max. length by : 0.5 m

taBLe FuMes pressure avaILaBLe

Cascade solution

∆P availableflue duct B23 Ø 80

∆P available withsingle non-return valve Ø 110/110

FS 50 150 110

FS 70 150 100


The kit is used to introduce combustion air from outside the installation area and comprises a hose to be installed in the mixer body.

Please consult the instructions supplied with the kit.

For air ducts (diameter and length), see the kit manual.

11.2 connector with c53 type

CT_

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601


12. Making the electrical connections

Electrical safety of the appliance is only guaranteed by correct earthing, in accordance with the current stan-dards and regulations.Connect the boiler to a 230V by means of the three-pin cable supplied with it make sure that the polarities are correctly connected.Use a double-pole switch with a contact separation of at least 3mm in both poles.In case you replace the power supply cable fit a HAR H05 VV-F’ 3x0.75mm2 cable with an 8mm diameter maximum outer sheath.

IMPORTANT: Check that the overall current drawn by accessories connected to the appliance is less than 2 amp. If the value is greater, a relay must be wired between the boiler control circuit board and the accessories drawing the higher current.

12.1 terMinal blocks access

• Isolate power to the boiler with the two-pole switch.• Remove the top facia panel cover (which is held by magnets).• Unscrew the two screws holding the facia panel in place.• Swing the facia panel forwards.

Main terminal block M1

• Remove the clip-on cover from terminal strip M1.• The main terminal block incorporates a fast blow 3.15 A fuse (figure 10). Remove the black fuse holder to

check and/or replace the fuse.

Terminal block M2

• Unscrew the fixing screw and remove the cover from terminal block M2.

Terminal block M3

• Unscrew the fixing screws and remove the main cover.

Figure 10

0205

23_0

400

Terminal Block M1

Terminal Block M2Cover

Cover

Facia panel


12.2 connecting the puMps

Figure 11

CG

_176

3 / 0

906_

2205

Turn the control box downward to access terminal boards M1 and M3 used for the electrical connections by removing the protective covers (see figure 11).

Terminals M1 a – b: connection of the Primary loop pump for the heating system (Plp)

Check the correct size and rating of the pump by referring to graph n° 1, which shows the boiler pressure losses.

Terminals M3 11 – 12: connection for heating pump (P1)Terminals M3 13 – 14: connection for hot water tank pump (PDHW)

The electrical specifications of the pump must be as follows:230 V AC; 50 Hz; 1 A max; cos f > 0.8.

If the specifications of the installed pump are different, a relay must be wired between the boiler control circuit board and the pump.It is advisable not to adopt any electrical connection other than those described.

connect earth to earth strip

Remove the resistor from terminals 9-10 of terminal strip M2 (figure 12), and connect the hot water priority NTC sensor, which is supplied as an accessory.The sensing element of the NTC device must be located in the recess provided on the storage tank (figure 12).The temperature and on-off programming of the domestic hot water supply are selected directly from the boiler control panel, as described in this manual under the user instruction headings.

12.3 connecting the hot water tank sensor


Figure 12

external power input 0÷10V

0602

_070

7/C

G17

6406

02_0

708/

CG

1765

safetycontact

room thermostat

Figure 13


Turn the control box downward to access terminal blocks M1 and M2 used for the electrical connections by removing the two protective covers (see figure 10).

Terminals 1-2: connections for the optional SIEMENS QAA73 (optional extra) room temperature regulator. These connections do not have any specific polarity.Remove the bridge between terminals 1-2 “TA” on terminal block M1.Read the instructions provided with the temperature regulator to ensure correct installation and program-ming.Terminals 3-4: room temperature thermostat “TA”. Thermostats with integral accelerator resistor must not be used. Check that there is no voltage across the ends of the two thermostat connection wires.Terminals 5-6: external safety contact (commercially available device).Terminals 7-8: connections for the optional SIEMENS QAC34 outdoor temperature sensor supplied with the boiler. Read the instructions provided with the outdoor temperature sensor to ensure correct installation.Terminals 9-10: connections for the optional domestic hot water priority sensor, for connecting single system boilers to external DHW boilers.

cLIp-In aGu 2.511terminals 3-4 L-n out: connection to signal lamp (230 V - 0,5 A max) for lockout alarm.terminals 5-6 L-n out: connection to signal lamp (230 V - 0,5 A max) for run mode.terminals X51 (1-2): connection to external power input 0÷10 V. pin 1: positive power input pin 2: negative power input

For low voltage signal lamp remove the internal wiring and feed with an external low voltage power supply.

12.4 description oF the electrical connections to the boiler

Electronic board parameter settings

1 Hold down buttons s t on the boiler panel for at least 6 seconds until the display indicates “-----”;

2 Press buttons t s +-+ in sequence: attention, this procedure accesses the “manufacturer” parame-ters. Do not modify any parameters apart from those shown below.

3 Press button s to select the parameters in ascending order; press button t to select the parameters in descending order. Press +/- to modify the display parameter;

The parameters to modify are h618 = 5; h623 = 50;

The changes are automatically saved when a new parameter is selected;

4 Press to save and exit the programming level.

LIst oF paraMeters

Parameter Description of parameters RangeDefaultsetting

Requiredsetting

618KonFIGeInGanr:Setting for programmable clip-in input

0 ÷ 8 0 5

623

panFoeXtechWeLLe:Threshold of the analogue signal from which the external heat demand is accepted (percentage of the maximum value of the analogue signal)

5 ÷ 95 5 50

12.4.1 connecting external signal (0÷10v)


12.5 connecting the qaa73 rooM teMperature regulator

The SIEMENS model QAA73 room temperature regulator, if required (optional accessory) must be connected to terminals 1-2 of terminal block M2 in figure 12.The link across terminals 3-4, provided for connection of a room temperature thermostat, must be removed.The settings of the domestic hot water temperature and domestic hot water production schedule must be made using this device.The timed program of the central heating circuit must be set on the QAA73 if there is a single zone, or in relation to the zone controlled by the QAA73 device.The timed program for the central heating circuit of the other zones can be set directly on the boiler control panel.

See the instructions provided with the QAA73 temperature regulator for the user parameter programming procedure.

QAA73: parameters which can be set by the installer (service)

By pressing the two PROG buttons together for at least three seconds it is possible to access the list of para-meters that the installer can display and/or set.Press either of these buttons to change the parameter to display or change.Press the [+] or [-] key to change the value displayed.Press either of the PROG buttons again to save the change.Press the information button (i) to quit programming.

Here follows a list of the most commonly used parameters:

0712

_210

7

Voltage (VDc)

Boiler heating performance according to the voltage on the connector (with voltage above 5V).

NB: Demand active = 10 Demand inactive = 0


- Fault messages

In the event of fault, the display panel on the QAA73 shows the flashing symbol . Press the information key ( ) to display the error code and a description of the fault (see table on paragraph 3.9).

Line no.

70

72

74

75

77

78

79

80

90

91

Default value

15

85

Light

On HC1

On

0

0

—.-

10

24 h/day

Range

2.5…40

25…85

Light, Heavy

on HC1on HC2on HC1+HC2 nil

On - off

0…360 min

0…360 min

2.5…40 —.- = not active

10…58

24 h/day TSP HC-1hTSP HCTSP DHW

Parameter

HC1 gradient heating curveSelection of central heating circuit temperature curve “kt”

HC1 max. output Central heating system maximum output temperature

Type of building

Room compensation Activation/deactivation of the influence of the room temperature. If it is deactivated, the outdoor temperature sensor must be installed.

Automatic adaptation of the temperature curve “kt” in relation to the room temperature.

Opt Start MaxMaximum time the boiler is switched on ahead of the timed program to optimise the temperature in the premises.

Opt Stop Max Maximum time the boiler is switched off ahead of the timed program to optimise the temperature in the premises.

HC2 gradient heating curve

DHW Red SetpMinimum temperature of the domestic domestic hot water DHW programSelection of the type of timed program for domestic hot water.24 h/day = always on PROG HC-1h = as HC1 central heating program less one hour PROG HC = as central heating program PROG DHW = specific domestic hot water program (see also program lines 30-36)


The SIEMENS model QAC34 outdoor temperature sensor must be connected to terminals 7-8 of terminal board M2 in figure 12.The procedures for setting the gradient of the temperature curve “kt” vary depending on the accessories con-nected to the boiler.

a) Without QAA73 room temperature regulator:

The temperature curve “kt” must be selected by setting parameter H532 as described in section 14 “setting the boiler parameters”.See graph 2 for selecting the curve referred to a room temperature of 20°C.The chosen curve can be shifted by pressing the (2), button (2) on the boiler control panel, and modifying the value displayed by pressing the and . keys. See graph 3 for curve selection. (The example show in graph 3 refers to the curve Kt=15).Increase the value displayed if the room temperature required is not reached inside the premises for central heating.

b) With QAA73 room temperature regulator:

The temperature curve “kt” must be selected by setting parameter 70 “HC1 curve” of the QAA73 room tem-perature control device as described in section 12.4 “QAA73: parameters which can be set by the installation (service) engineer”.See graph 4 for selecting the curve referred to a room temperature of 20°C.The curve is shifted automatically on the basis of the room temperature set using the QAA73 climate control.If the system is divided into zones, the temperature curve “kt” relating to the part of the system not controlled by the QAA73 must be selected by setting parameter H532 as described in section 14 “setting the boiler parameters”.

Graph 2 Graph 3

TM = Flow temperature Te = Composite outside temperatureSth = Kt Curve

TM = Flow temperature Te = Composite outside temperature

0205

23_0

600

0205

23_1

000

12.6 connecting the outdoor teMperature sensor probe

Graph 4

c) With AGU2.500 for control of a low temperature system:

Refer to the instructions provided with the AGU2.500 accessories for connection and control of a variable temperature zone.


13. adjusting the gas valves

Figure 14

LEGEND:Pi: Gas supply pressure

connection pointP out: Pressure connection point for

measurement of the OFFSETV: Gas flow adjuster screwK: OFFSET adjuster screw

0712

_091

2 / C

T_07

54Mixer

Gas valve


Proceed as follows to adjust the single gas valve:

• Insert the flue analysis probe into the flue sampling hole as instructed in section 17 (figure 17).• Press and hold the and keys on the control panel simultaneously for 7 seconds until the symbols

appear on the display in the position shown in figures 15a and 15b . You are now in ‘calibration mode’.

• Press the key to set the maximum heat output, with the display showing 100% (figure 15a).

caution: in the event of the boiler failing to ignite, or when replacing the mixer / gas valve group, the recommended procedure is to tighten the adjuster screw (v) fully and then back off 10 turns for natural gas (G20) and 5 turns for propane gas (LpG), repeating the steps described below.

• Turn the adjuster screw V on the gas valve until you achieve the CO2 levels shown in table 2.1 for natural gas (G20) and in table 2.2 for propane (LPG):

- Turn the screw anti-clockwise to increase the CO2 level. - Turn the screw clockwise to decrease the CO2 level.

• Press the key to set the minimum heat output, with the display showing 0% (figure 13b).• Remove the protection cap and turn the adjuster screw K on the gas valve until you achieve the CO2 levels

shown in table 2:

- Turn the screw clockwise to increase the CO2 level. - Turn the screw anti-clockwise to decrease the CO2 level.

gas conversion

IMportant: in the event of converting the boiler from natural gas (G20) to propane (LPG), the following operation must be carried out before proceeding to adjust the gas valve as described above:

• Screw 5 turns the adjuster screw (V).• Set parameters h536 - h541 - h608 - h609 - h610 - h611 - h612 - h613 by way of the display on the

control panel.

The values to be set are given in tables 2.1 and 2.2. The programming methods are described in chapter 14.

Figure 15a

0307

_220

1

Figure 15b⇑ ⇑

0502

_211

0


The boiler parameters may only be modified by professionally qualified staff proceeding as follows:

a) Press the , keys on the boiler’s front panel together for about 3 s until the parameter H90 appears on the display;

b) Press the keys to select the parameter for modification;

14. setting the boiler paraMeters

Table 2.2

table 2.1

Gas consumption at 15 °C 1013 mbar Gas G20 - 2h - 20 mbar 50 70

PCI MJ/m3 34,02 34,02

Consumption at max. heat output m3/h 4,91 7,08

Consumption at min. heat output m3/h 1,29 1,46

CO2 max. heat output % 8,7 8,9

CO2 min. heat output % 8,4 8,4

Parameters h536-h613 (rpm) at maximum power 6100 6400

Parameters h541-h610 (pwm %) at maximum power 85 100

Parameter h612 (rpm) at minimum power 1700 1450

Parameter h609 (pwm) at minimum power 13,5 11

Parameter h611 (rpm) ignition load 2600 2500

Parameter h608 (pwm) ignition load 20 18

Gas consumption at 15 °C 1013 mbar Gas G31 - 3p - 37 mbar 50 70

PCI MJ/kg 46,34 46,34

Consumption at max. heat output kg/h 3,6 5,2

Consumption at min. heat output kg/h 0,95 1,54

CO2 max. heat output % 10,2 10,2

CO2 min. heat output % 9,8 9,8

Parameters h536-h613 (rpm) at maximum power 5700 6000

Parameters h541-h610 (pwm %) at maximum power 75 100

Parameter h612 (rpm) at minimum power 1600 1900

Parameter h609 (pwm) at minimum power 13 14

Parameter h611 (rpm) ignition load 3800 3800

Parameter h608 (pwm) ignition load 30 30


( * ) For these parameters see section 10.1 - 10.2 - 10.3 (hydraulic system).

parameter n.

h90

h91

h505

h507

h516

h532

h533

h608

h611

h609

h541-h610

h612

h536-h613

h544

h545

h552( * )

h553( * )

h615

h632( * )

h641

h657

Description

Minimum D.H.W. temperature setting (°C).

D.H.W. activation program (0=active; 1=not active)

Maximum temperature (°C) of the central heating circuit HC1 corresponding to:- the main circuit in systems with just one zone;- the circuit of the zone where the QAA73 room temperature control device is installed in case

of systems with more than one high-temperature zone;- the high temperature zone circuit in mixed systems and if the SIEMENS AGU2.500 accessory

is used.

Maximum temperature (°C) of the central heating circuit HC2 of a system with more than one zone, corresponding to the circuit of the low-temperature zone if the SIEMENS AGU2.500 accessory is used.

Automatic Summer / Winter switching temperature (°C).

Selection of temperature curve of central heating circuit HC1 (see Graph 2)

Selection of temperature curve of central heating circuit HC2 (see Graph 2)

PWM (%) Setting: Ignition load

Speed setting (rpm) : Ignition load

PWM Setting (%) : minimum power PWM Setting (%) : maximum power Central heating / Domestic hot water Speed setting (rpm) : minimum power

Speed setting (rpm) : maximum power Central heating / Domestic hot water

Pump post-circulation time in central heating mode (min)

Burner operating pause time between two start-ups (s)

Hydraulic system setting (see instructions provided with the SIEMENS AGU2.500 accessory)H552 = 50 with AGU2.500 and QAA73 H552 = 80 with RVA 47

Configuration of heating circuitsH553 = 12 with AGU2.500

Programmable function:

Heat demand to be supported by the system pumpH632 = 00001111 with AGU2.500 and RVA 47

Fan overrun time setting (s)

Setpoint of autonomous ANTILEGIONELLA function

60...80 °C = setting temperature range 0 = function inactive

Factory setting

10

1

80

80

20

15

15

Seetable 2

10

180

2

21

9

00001100

10

0

c) Press the and keys to modify the parameter;d) Press the key to exit the programming function.

The following are the parameters generally used:

Table 3

If the electronic circuit board is replaced, make sure that the parameters set are those specific to the boiler model, as indicated in the documentation available from the authorised Service Centre.


The boiler has been designed in full compliance with European reference standards and in particular is equipped with the following:

• Overheatsafetythermostat This thermostat interrupts the gas flow to the main burner in case the water contained in the circuit has ove-

rheated. Under these conditions the boiler locks out and can only repeat the ignition procedure by pressing of the reset button on the boiler after the cause of the trip has been rectified.

It is strictly forbidden to disable this safety device.

• Fluethermostat This device, positioned on the flue inside the boiler, interrupts the flow of gas to the burner if the temperature

exceeds 90 °C. After verifying the cause of the trip, press the reset button positioned on the thermostat itself, then press the reset button on the boiler.

It is forbidden to disenable this safety device

• Flameionizationdetector The flame sensing electrode guarantees safety of operation in case of gas failure or incomplete interlighting

of the main burner. Under such conditions the boiler is locked out. You must press the reset button on the boiler to restore the normal operating conditions.

• Pumpoverrun The electronic control system keeps the pump operating for 10 minutes in central heating mode after the

room temperature thermostat has switched off the main burner.

• Frostprotectiondevice The boilers electronic management includes a “frost protection” function in the central heating system which

operates the burner to reach a heating flow temperature of 30°C when the system heating flow temperature drops below 5 °C.

This function is enabled as long as the boiler is connected to the a.c. power supply gas supplies and the pressure in the system is as specified.

• Pump-blockingprevention In case there is no call for heat either from the central heating system or from the DHW system for 24 hours

continous the pump will automatically switch on for 10 seconds.

• Hydraulicpressuresensor This device enables the main burner only to be switched on if the system pressure is over 0.5 bar.

• Gaspressureswitch This device enables the burner only to be switched on if the gas pressure is over 12 mbar.

15. control and operation devices


Drill a hole in the flue at a distance from the boiler equivalent to twice the diameter of the flue to measure combustion efficiency and combustion flue composition in accordance with the rules in force. Use this hole to measure the following parameters:• Combustion flue temperature• Oxygen (O2) or carbon dioxide (CO2) concentration.• Carbon monoxide (CO) concentration.Measure the temperature of combustion air near the air inlet to the boiler. The necessary hole must be made by the technician responsible for the heating system when the system is first started up, and must then be closed to ensure that the flue remains properly sealed during normal operation.

17. check oF coMbustion paraMeters

Figure 17

Figure 16

16. positioning oF the ignition and FlaMe sensing electrode

0503

_220

4

Important! Close the flue test point hole on completion of measurements.

BOILER FLUE TEST POINT HOLE

0811

_170

3 / C

T_07

82


To facilitate measurement of the combustion efficiency and improve the cleanliness of the production products, the chimney sweep function can be activated by proceeding as described below:1) Press the (2-3) together until the pointer “ ” appears on the display alongside the symbol (about 3

seconds but no more than 6 seconds). In these conditions, the boiler operates at the maximum heat output in central heating mode.

2) Press either of the buttons to exit the function

0204

29_0

200

Figure 18

To ensure the boiler operates at peak efficiency, the following checks must be performed every year:• Check on the appearance and tightness of the gas and combustion circuit gaskets;• Check on the condition and position of the ignition and flame sensing electrodes (see section 16);• Check on the condition of the burner and its fixing to the aluminium flange;• Check for any dirt in the combustion chamber. Use a vacuum-cleaner for this cleaning operation;• Check that the gas valve is calibrated correctly (see section 13);• Check that there is no dirt in the siphon;• Check on the central heating system pressure;• Check on the central heating expansion vessel pressure.

18. activating the chiMney sweep Function

19. annual service


Figure 19

Key:1 Water pressure gauge2 Siphon (condensate)3 Central heating ntc sensor4 105°C overheat safety thermostat5 Gas valve6 Heat exchanger7 Flame detector electrode (ionisation probe)8 Burner9 Ignition electrode10 Mixer with venturi11 Air/gas diaphragm12 Fan13 Flue joint14 Automatic air vent15 Hydraulic pressure sensor16 Boiler drain point17 Joint flue with flue thermostat18 Flue thermostat19 Gas pressure switch20 Seat of air intake

20. boiler scheMatic

CT_

0817

/ 09

06_2

401


21. illustrated wiring diagraM

CT_

0756

/ 09

06_2

206


Boiler model FS 50 70Category II2H3P II2H3P Maximum heat input (net/gross) kW 46,4-51 67-73,7Minimum heat input (net/gross) (G20) kW 12,2-13,4 13,8-15,2Minimum heat input (net/gross) (G31) kW 12,2-13,4 19,9-21,9Maximum heat output 75/60°C kW 45 65 kcal/h 38.700 55.900Maximum heat output 50/30°C kW 48,7 70,3 kcal/h 41.882 60.458Minimum heat output 75/60°C (G20) kW 11,8 13,4 kcal/h 10.148 11.524Minimum heat output 75/60°C (G31) kW 11,8 19,3 kcal/h 10.148 16.598 Minimum heat output 50/30°C (G20) kW 12,8 14,5 kcal/h 11.008 12.470Minimum heat output 50/30°C (G31) kW 12,8 20,9 kcal/h 11.008 17.974Useful efficiency according to 92/42/CEE directive — ★★★★ ★★★★

Central heating system max. pressure bar 4 4

Heating circuit temperature range °C 25÷80 25÷80Flue type — B23 - B23P - C53* Flue duct diameter mm 80 80Max. flue mass flow rate kg/s 0,022 0,031Min. flue mass flow rate kg/s 0,006 0,007Max. flue temperature °C 72 73NOx class — 5 5 Type of gas used — G20 G20 — G31 G31Natural gas feeding pressure 2H mbar 20 20Propane gas feeding pressure 3P mbar 37 37

Gas Consumption (NG) m3/hr 4,91 7,08 Minimum Operating Pressure Bar 1 1High Level Ventilation to BS6644 boiler room cm2 92,8 113,4Low Level Ventilation to BS6644 boiler room cm2 185,6 226,8Mechanical inlet to BS6644 m3/sec 0,038 0,056Water Flow at 20°K Δt lit/sec 0,053 0,77Hydraulic Resistance at 20°K Δt kPa 25 25Cold Feed Size to BS6644 mm 25 25Safety valve size to BS6644 (open vent) mm 19 19Open vent BS6644 mm 32 32Maximum Flow Temperature °C 72 73Water Content lit 5,1 6,5 Power supply voltage V 230 230Power supply frequency Hz 50 50Rated power supply W 900 110

Net weight kg 60 68Dimensions height mm 850 850 width mm 450 450 depth mm 621 693

* C53 (only with air intake kit)

22. technical data

Baxi Commercial DivisionWood Lane, Erdington, Birmingham B24 9QP Email: [email protected]

Sales:

0845 070 1056Technical:

0845 070 1057 heating specialists

Commercial sales technical & service enquiries

Tel: 0845 070 1055Fax: 0845 070 1059Sales hotline: 0845 070 1056Technical helpline: 0845 070 1057Service hotline: 0845 070 1058e-mail: [email protected]: www.pottertoncommercial.co.uk

Spares

Potterton Commercial spares are available nationwide through the interpart network of approved stockists.Alternatively please contact:-

InterpartBrooks HouseCoventry RoadWarwick CV34 4LL

Tel: 0844 871 1540

Applications & Installations

Our experienced technical support team are available to offeradvice on any aspect of heating system design and boilerinstallation.

Please contact: 0845 070 1057

Commercial service offices

Our service organisation covers the whole of the UK to look afteryour needs for all Potterton Commercial products.

Our service office offers a wide range of specialised servicesincluding:

• Burner commissioning for all fuels• Boiler service contracts• Breakdown and repair services• Burner and boiler replacement• Oil/gas conversions• Water treatment and descaling• Packaged units

All descriptions and illustrations contained within this leaflet havebeen carefully prepared, but we reserve the right to makechanges and improvements in our products which may affectthe accuracy of the information in this leaflet.

sirius fs 50-70 - potterton commercial

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